Acoustical wall covering



June 243, 1936- c. K. Roos ET A1. 2,045,312

' ACOSTICAL WALL COVERING Filed July 2o', 1955 2 sheets-sheet 1 [n @onions June 23, 1936. c. K. Roos ET A1.

ACOUSTICAL WALL COVERING 2 Sheets-Sheet 2 Patented June 23, 1936 UNITED STATES ACoUs'rIoAL WALL Govt-:RING

Carlisle K. Roos, Wheaton, and George D. King,

Chicago, Ill., assignors to United States Gypsum Company, Chicago, Ill., a corporation of Illinois Application July 20, 1933, Serial No. 81,307

22 Claims.

This invention relates to improvements in acoustical construction and has particular relation to acoustical coverings for walls, ceilings, and the like, all of whichjare intended to be comprehended Within the generic term wal1s.

'I'he use of various types of rigid sound-absorbing materials of a porous nature, or the like, as acoustical wall coverings, has been known in the art for many years. Such materials have l0 included porous plasters, fibrous tile products,

ceramic tile,l aggregations of slag, cork, and theA like, mineral wool slabs, etc. Many of these products cannot be painted without destroying their acoustical qualities, because the paint lls the pores at the surface and prevents entrance of the sound Waves which impinge thereon. Paintability has been achieved to somel extent with some tile products by making the same with very rough open surfaces, but such surfaces present a very poor and non-uniform appearance and are lacking in the desired qualities of smoothness and light reection.

The present invention is directed to arrangements for overcoming the above-mentioned difi'lculties and objections.

The primary object of the invention is to provide a construction in which a rigid sound-absorbing materialsof relatively poor or unsatisfactory appearance may `be used as the primary absorbing medium, while the finished product of construction may be made to have a good appearance and desirable qualities of cleanability, paintability, high light deflectivity and comparative freedom fromvcollection of dust and dirt.

A further object of the invention is to provide a product or construction,v the surface of which may be readily modified to satisfy the desires of individuals or. the requirements of particular installations.

` In a copending application filed Oct. 4, 1933,

Serial No.- 692,078 in the names of the inventors in the present case, there is disclosed and claimed an invention comprising an acoustical construction made up of a compressible sound-absorbing material, faced with a iiexible membrane which is substantially impervious to the passage of air.

The present invention likewise employs a substantially impervious membrane, but includes a rigid sound-absorbing material rather than a compressible material. This invention is based upon/,the discovery that sound-absorbent products which are not easily compressible or flexible may be surfaced with a flexible but substantially impervious membrane, providing the membrane ispbcedlooselyonthewhcect theabsorbent material and not glued or otherwise secured thereto over the entire surface thereof. Various adaptations of the invention embodying this principle aredescribed in detail hereinafter, by way of example of the numerous modiflca- 5 tions which may be employed.

'I'he invention will be better understood upon reference to the detailed description appearing hereinafter, in conjunction with the accompanying drawings forming a part hereof, in which: l0

Figure 1-is a fragmentaryfsectional view of a wall which has been acoustically treated in accordance with the invention;

Fig. 2 is a fragmentary front elevational view of the construction shown in Fig. 1, indicating l5 by the line l-|, the plane on which the sectional view of Fig. 1 is taken;

Fig. A3 is an enlarged fragmentary section view of yone of the wall-covering elements l'shown in Figs. 1 and 2, taken on a plane such as that 20 indicated by the line 3-3 in Fig. 2; Fig. 4 is a view similar to Fig. 3 but showing a modified type of construction of one of the wallcovering elements;

Fig. 5 is an enlarged fragmentary front ele- 25 vvational view of the element shown in Fig. 3, with certain of the parts broken away to illustrate the construction more clearly;

Fig. 6 is a view similar to Fig. 5, but illustrati ing the-modified type of construction of Fig. 4; 30

Fig. 7 is a fragmentary sectional view of a Wall, similar to Fig. 1 but showing a diiferent type of construction;

Fig. 8 is a fragmentary front elevational view cf the construction cf Fig. '1, indicating by the 35 line 1--1 the plane on which the sectional View of Fig. 7 is taken;

Fig. 9 is an enlarged fragmentary sectional view taken on the same plane as Fig. 7, but illustrating the construction in greater detail by 40 reason of its enlargement; and

Fig. 10 is an enlarged fragmentary front elevational view of the construction shown in Fig. 9, with parts broken away to give a more detailed illustration. 45

Referring rst to Figs. 1 to 6 of the drawings, a

. Wall of any ordinary type is illustrated by way of example as being formed of hollow tile or slabs II of gypsum or the like. Over this surface the usual coat or coats of plaster l2 are applied in 50 the usual manner, and this plastered surface is covered, for the purposes of acoustical correction, by a plurality of slabs or tiles I3, which are formed in accordance with the invention. These tiles may be secured to the plastered surface by 5,-,

a layer of cement or adhesive I4, as shown, or by any desired type of mechanical or other securing means. For the purposes of decorative appearance, the tiles may be suitably formed with beveled edges, as illustrated, and they may be made of any desired dimensions. A suitable tile may be made approximately 12" square and 1" thick, to give ,a good appearance and to be easily handled.

The tiles or slabs I3 may be made of any desired type of rigid sound-absorbent material, which materials are well known in the art, and va number of which have already been listed herein by way of example. The drawings are intended to illustrate ber boards or. slabs of any well-known type, but it will be readily understood that cementitious or ceramic materials, bonded aggregations or any other compositions may be utilized in the same manner.

All of the materials above mentioned, While highly effective as sound absorbents, present a poor appearance and have a comparatively rough and uneven surface of poor light reflectivity. 'Ihey are also poorly adapted for painting and cleaning by reason of the fact that paint will iill the pores at the surface and destroy the acoustical properties, while' cleaning will impair the surface appearance or result in uneven removal of a considerable quantity of fibrous or similar material, as Well as being comparatively ineffective' in any event.

According to the present invention, the tiles or slabs I3 are faced with membranes I5 which are substantially impervious to the passage of air. In this respect such membranes are different from those of the prior art which have been made of a porous or perforated material. The

pores or perforations in such prior art membranes have detracted in a large measure from the desired qualities of appearance and protection to the sound-absorbing material behind the same. With the substantially impervious membranes to which reference is made herein, these objections are entirely overcome, and the finished product or construction presents a surface of pleasing appearance and one which may be readily cleaned and painted and which may be made to have any desired degree of light reflectivity.

The membranes I5 may be made of numerous substantially impervious materials, the only other essential characteristic being flexibility, so that the membranes may vibrate freely under the impact of sound waves. Suitable materials for the construction of the membranes are various grades and types of paper, metal foil, oil cloth, treated fabrics, wall paper, "cellophane, sheet mica, or any other material having -similar` qualities.

The only requirement as to the securing of the membranes is placed over the surfaces of the sound-absorbent material is thatthe membranes shall be free to vibrate independently of the absorbing material over a major portion of the exposed area. A suitable method o-f attachment of the membranes is illustrated in the drawings, which are intended to depict the use of glue or other adhesive along comparatively narrow strips or bands I6 around the edges of each of the slabs or tiles. For this purpose a flexible glue gives desirable results, because the membranes may be secured in place under sufcient tension to prevent sagging, but not great enough to warp the slabs or tiles or to impair their acousticalv efficiency. It will be understood, however, that the membranes 'may be attached by nailing or other means, mechanical or otherwise, so long as the above noted requirements are complied with.

Figs. 3 and 5 illustrate the use of a membrane I5 of uniform thickness and appearance which may be constituted by ordinary or treated paper of any kind, or any of the other materials hereinabove enumerated. In Figs. 4 and 6 a modied type of membrane I5a is illustrated and consists of crinkled or embossed paper or metal foil, or the like. A further slight modification embodiedV in this form of construction resides in the fact that the membrane is extended down over the beveled edges of the tiles or slabs, whereas in the construction illustrated in Figs. 3 yand 5, the membranes terminate along the lines where the beveled edges begin. Either arrangement may, of course, be used as4 desired.

When the membranes are made of paper, it is preferable to have the same conditioned to a suitable water content, giving some degree of expansion before application, so that the desired tension will be maintained under varying conditions of humidity. The use of crepe or embossed paper is advantageous in avoiding sagging under high humidity conditions, as well as avoiding excessive tension at any time.

It will be seen that the slab or tile unit type of construction is readily adapted for application to a completed wall. The invention is not limited to this type of application, however, but may be applied with equal effectiveness in the original Yconstruction of a building or the like. Figs. 7 to 10 of the drawings illustrate ythe application of a coat of acoustic plaster to a Wall surface. In these figures a different type of construction is illustrated as a further example, consisting of wood studs I1 to which are nailed plaster boards I8 forming a plaster-receiving base or lathing.

As shown in Fig. 9, such plaster boards may consist of a gypsum core Ia and paper covering sheets I8b, according to Well-known construction.l These boards are secured to the studs v I'I by nails I9 in the usual manner and a coating of ordinary plaster 20 may be applied over the surface of the" boards to provide a base coat upon which a layer of acoustical plaster 2| is subsequently applied. Acoustical plasters of various compositions are Well known in the art and do not require detailed discussion herein. It will suilce to say that such plasters ordinarily consist of a porous material, whereby absorption of sound is obtained.` f

The present invention is embodied in this type of construction by the use of a membrane coveringv 22 which may be applied in sheets of any desired size. Such membranes are secured in place over the surfaces of the acoustical plaster in much the same way that the individual membranes are applied in the above-described slab or tile construction, that is, by narrow strips or bands of adhesive23 or other suitable securing means. The application of the adhesive in comparatively widely-spaced bands orA spots accomplishes the pur-poses of the invention by leaving the major portion of the membrane free to vibrate with respect to the sound-absorbant material directly behind it.

With any of the above-described types of construction the exposed surfaces of the membranes may be painted as desired without greatly affecting the acoustical eillciency of the complete construction. .It wil1 be understood, of course, that in an installation where one or more coats 0I' termined for any desired type of installation and is not of a critical' nature. The membranes may also be selected from a wide range of equivalents to give any desired characteristics of cleanability, light reflection, etc.

-From the foregoing, it will be seen that the invention resides in the provision of a substantially impervious membrane extending over the surface of a rigid sound-absorbing material and secured in place in such a manner that the major portion thereof will vibrate independently of the sound-absorbing material. The elimination of pores and perforations in the membrane provides a great improvement in the appearance and other desired characteristics lof the installation over those which have been used heretofore. Moreover, the discovery of the fact that the membranes maybe secured in place over the surfaces of the rigid sound-absorbing material without being spaced outwardly therefrom, provides an economical and desirable type of construction which has been unknown heretofore.

In referring to the membranes as being subb stantially impervious to the passage of air, Iit will be understood that a limitation tocompletely impervious and non-porous products is not in'- tended. For example,- paper and similar prodactual-contact with the covering vat every point on the surface thereof, but only that no intervening space is intentionally provided. Minute spacing, resulting from slight sagging on the part of the membrane or irregularities in the surface of the sound-absorbent material, are not regarded as placing the membrane out of substantial contact with the sound-absorbent material.

Other terms used in the foregoing description and appended `claims will be readily understood from the context. The term wall,a s above indicated, is used generically to designate both.

While only certain specific embodiments of the i invention have been shown and described in detail herein, it will be readily understod by those skilled in the art that various changes and modiiications in the details of construction and' arrangement of parts may be made without departing from the spirit and scope of the invention, as set forth in the appended claims.

What is claimed as new and is desired to secure by Letters Patent, therefore, is:

1. An acoustical construction comprising a' wall having a normally exposed surface, a covering for ysaid surface of rigid, sound-absorbent material, and a flexible membrane substantially impervious to the'passage of air extending over the face of said covering and in contact therewith over substantially the entire surface thereof, but free to vibrate with respect thereto over the principal portion of such surface.

2. An acoustical lconstruction comprising a wall having a normally exposed surface, a covering for 'said surface of rigid, sound-absorbent material, and a flexible membrane substantially impervious to the passage of air extending over the face ofsaid ,covering and adhesively secured thereto at spaced intervals. 3. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material, and a flexible membrane substantially impervious to 'the passage of air extending over the face of said covering and in contact therewith over substantially the entire surface thereof and adhesivelysecured thereto at spaced intervals. i

4. An acoustical construction comprising a wall having anormally exposed surface, a -covering for said surface of rigid, sound-absorbent material, and a exible membrane substantially impervious to the passage of air extending over the face of said covering and in contact therewith oversubstantially the .entire surface thereof but free to vibrate with respect thereto over the principal p ortion of such surface, said membrane being of a cleanable material.

5. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material, and a flexible membrane substantially impervious to the passage of air extending over the face of said covering and in contact therewith over substantially the entire surface thereof but free to' vibrate with respect thereto over the principal portion of such surface, said membrane being of \a paintable material.

6. An `acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material, and a flexible membrane extending over the face of said covering and in contact therewith over substantially the entire surface thereof but free to Aavibrate with respect thereto over the principal portion of such surface, said membrane being, paintedto render the same substantially impervious to air and water vapor.

7. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material, and a flexible membrane substantially impervious to the passage of air extending over the face `of said covering and in contact therewith over substantially the entire surface thereof but free to vibrate with respect thereto over the principal portion of such surface, said membrane' being of a material of relatively high light refiectivity.

8. An acoustical construction comprising a wall having a normally xposedlsurface, a covering for said surface of rigid,sound`absorbent material, and a flexible membrane substantially impervious to the passage of air extending over the face of saith covering and in contact therewith over substantially the entire surface thereof but free to vibrate with respect thereto over the principal portion of such surface, said membrane 7 being of a material having a smooth and uniform surface.

9. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material, and a exible membrane substantially impervious to the passage of air extending over theA face of said covering and adhesively secured thereto at spaced intervals by a exible glue.

10. An acoustical construction comprising a .wall having a normally exposed surface, a covertervals.

11. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material, and a flexible membrane of crepe-like paper substantiallyimpervious to the passage of air extending over the face of said covering and adhesively secured thereto at spaced intervals.

12. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material formed in tile-like units, and a flexible membrane substantially impervious to the passage .of air extending over the face of each of said units and in contact therewith over substantially the entire surface thereof.

13. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material formed in tile-like units, and a flexible membrane substantially impervious to the passage of air extending over the face of each of said units and adhesively secured thereto at spaced intervals.

14. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material formed in tile-like units, and a flexible membrane substantially impervious to the passage of air extending over the face of each of said units and adhesively secured thereto along relatively narrow bands at the edges thereof.

15. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material formed in tile-like units, and a exible membrane substantially impervious to the passage of air extending over the face of, each of said units and adhesively secured thereto at spaced intervals by a flexible glue. v

16. An acoustical construction comprising a wall including an extensive surface layer of rigid, sound-absorbentmaterial and a flexible membrane substantially impervious to the passage of air extending over the face of said surface layer and in contact therewith over substantially the 5 .18. An acoustical construction comprising a wall including an extensive surface layer of rigid, sound-absorbent material and a flexible membrane substantially impervious to the passage of air extending over the face of said surface layer and in contact therewith over substantially the entire surface thereof and adhesively secured thereto at spaced intervals.

19. An acoustical construction comprising a wall including a continuous surface layer of acoustic plaster and a exible membrane substantially impervious to. the passage of air extending over the face of said surface layer and in contact therewith over substantially the entire surface thereof and secured thereto at spaced intervals. 30

20. An acoustical construction comprising a wall having a normally exposed surface, a covering for said surface of rigid, sound-absorbent material, and an impervious paper membrane eX- tending over the face of said covering and in contact therewith over substantially the eri-1re surface thereof, but free to vibrate with respect thereto over the principal portion of such surface.

21. An acoustical construction comprising va 40 wall having a normally exposed surface, a covering fo-r said surface of rigid, sound-absorbent material, and an impervious metal foil membrane extending over the face of said covering and in contact therewith over substantially the entire surface thereof, but free to vibrate with respect thereto over the principal Aportion of such surface.

22. An acoustical construction comprising a wall having a normally exposed surface, a'covering for said surface of rigid, sound-absorbent material, and arrimpervious cellophane membrane extending over the f'ace of said covering and in contact therewith over substantially the entire surface thereof, but free to vibrate with respect thereto over the principal portion of said surface.

CARLISLE K. ROOS. GEORGE D. KING. 

